Kemper 460plus User manual

460plusStalkBuster™Rotary
HarvestingUnit
*OMKM128769*
OPERATOR'SMANUAL
460plusStalkBuster™Rotary
HarvestingUnit
OMKM128769ISSUEE1(ENGLISH)
MaschinenfabrikKemperGmbH&Co.KG
EuropeanEditions
PRINTEDINU.S.A.

Introduction
KM00321,0000A73-19-12MAY20-1/1
Foreword
READTHISOPERATOR'SMANUALcarefullytolearn
howtooperateandserviceyourmachinecorrectly.Failure
todosocouldresultinpersonalinjuryorequipment
damage.Thisrotaryharvestingunitmaybeinstalledand
operatedonaforageharvesteronly.Theusermustbe
entitledtodriveaforageharvesteronpublicroads.This
manualandsafetysignsonyourmachineareavailablein
otherlanguages.Toorder,seeyourKEMPERdealer.
THISMANUALSHOULDBECONSIDEREDapermanent
partofyourmachineandmustremainwiththemachine
whenyousellit.
MEASUREMENTSINTHISMANUALaregiveninmetric
units.ThecustomaryU.S.unitequivalentsarealso
quoted.Onlyusecomponentsandboltsthatfit.Metric
andinchfastenersmayrequireaspecificmetricorinch
wrench.
RIGHT-HANDANDLEFT-HANDsidesaredetermined
byfacinginthedirectiontheimplementwilltravelwhen
goingforward.
THETERM"TRANSPORT"referstoarotaryharvesting
unitmountedonaforageharvesterandtransportedfrom
AtoBontheforageharvester.
THETERM"HAULAGE"referstoarotaryharvestingunit
loadedonaflatbedcarrierandtransportedfromAtoB
ontheflatbedcarrier.
LOADINGANDHAULAGEofthisrotaryharvestingunit
mustbeperformedonlybypersonsfamiliarwithhowthe
loadissecured,andwhocanprovideevidenceofthis.
WRITEPRODUCTIDENTIFICATIONNUMBERS(P .I.N.)
intheSpecificationorIdentificationNumberssection.
Recordallnumbersexactly.Intheeventoftheft,these
numbersmayprovevitalintracingyourproperty.Your
KEMPERdealerneedsthesenumberswhenyouorder
parts.Filetheidentificationnumbersinasecureplace
awayfrommachine.
BEFOREDELIVERINGTHISMACHINE,yourdealer
performedapredeliveryinspection.
INTENDEDUSE:THISROTARYHARVESTINGUNIT
maybeusedONLYforharvesting:
•thick-stemmed,flexibletypesofplantsuchascorn,
elephantgrassorbamboo
•thin-stemmedtypesofplantsuchasgraincrop,mustard
Useinanyotherwayisconsideredascontrarytothe
intendeduse.Themanufactureracceptsnoliabilityfor
damageorinjuryresultingfromthismisuse,andthese
risksmustbebornesolelybytheuser.
THISROTARYHARVESTINGUNITMUSTNOTbe
usedtomanuallytransfermaterialsofanysortandisnot
suitableforthetransferandchoppingof:
•woodyplantswithadiametergreaterthan1mm
•woodintendedforchipping
•animalfeedsuchasbeets
•metallicobjects
•materialsthatincludestones
Compliancewithandstrictadherencetotheconditions
ofoperation,serviceandrepairasspecifiedbythe
manufactureralsoconstituteessentialelementsforthe
INTENDEDUSE.
THISROTARYHARVESTINGUNITMUSTbeserviced
andrepairedONLYbyindustrialmechanics,fittersor
personswithcomparablequalifications.Theelectrical
systemmustberepairedonlybyelectricians.Theaccident
preventionregulations,allothergenerallyrecognized
regulationsonsafetyandoccupationalmedicineandthe
roadtrafficregulationsmustbeobservedatalltimes.It
isnotpermittedtoalterthemachinetoacceptmaterials
otherthanthosepermittedinitsintendeduse.Any
arbitrarymodificationscarriedoutonthisrotaryharvesting
unitwillrelievethemanufacturerofallliabilityforany
resultingdamageorinjury.
THISROTARYHARVESTINGUNITMUSTNOTbe
operatedintheUnitedStatesandCanada.
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Contents
Page
PredeliveryInspection
PredeliveryChecklist...................................CLIST-1
DeliveryChecklist.........................................CLIST-1
After-SaleChecklist......................................CLIST-1
IdentificationView
IdentificationView...............................................00-1
Safety
RecognizeSafetyInformation............................05-1
FollowSafetyInstructions...................................05-1
UnderstandSignalWords...................................05-1
ObserveRoadTrafficRegulations......................05-2
OperatorAbility...................................................05-2
UseSafetyLightsandDevices...........................05-2
PrepareforEmergencies....................................05-3
WearProtectiveClothing....................................05-3
CheckMachineSafety........................................05-3
GuardsandShields............................................05-3
StayClearofHarvestingUnit.............................05-4
KeepHandsAwayFromKnives.........................05-4
StoreAttachmentsSafely...................................05-4
PracticeSafeMaintenance.................................05-5
StayClearofRotatingDrivelines........................05-5
ServiceMachinesSafely....................................05-6
SupportMachineProperly..................................05-6
AvoidEntanglement...........................................05-6
AvoidHigh-PressureFluids................................05-7
TransportwithHarvestingUnitInstalled.............05-7
BallastingforSafeGroundContact....................05-7
RemovePaintBeforeWeldingorHeating..........05-8
AvoidHigh-PressureJetonSafetyDecals.........05-8
Decommissioning:ProperRecycling
andDisposalofFluidsandComponents.......05-9
ProtectAgainstNoise.........................................05-9
ParkMachineSafely.........................................05-10
SafetyDecals
PictorialSafetySigns..........................................10-1
ReplaceSafetySigns.........................................10-1
Operator’sManual..............................................10-1
RepairandMaintenance....................................10-2
RotatingBlades..................................................10-2
StalkBuster™MulchingUnits.............................10-2
Accumulator-StalkBuster™MulchingUnits......10-3
FoldingArea.......................................................10-4
Page
StayClearofRotaryHarvestingUnit..................10-4
RotatingDrums...................................................10-5
FoldableFrame..................................................10-5
InputTransmission.............................................10-6
Haulage
LoadingwithaCrane..........................................15-1
SecuretheRotaryHarvestingUnitfor
Transport(LashingPoints).............................15-3
PreparingtheRotaryHarvestingUnit
Unpacking...........................................................20-1
WorkingUnderaRaisedRotary
HarvestingUnit...............................................20-1
RemovingtheTransportPallet...........................20-2
MountingDustProtectionRubbers.....................20-2
SetOuterProtectiveCoversinto
OperatingPosition..........................................20-3
AdjustingtheHeightofScraper
SheetsontheCenterStalkBuster™
MulchingUnits................................................20-4
AdjustingtheInnerSkidShoes..........................20-5
AttachingtoaCLAASForageHarvester
CompatibilityChart.............................................30-1
TireCombinations..............................................30-1
BallastingHarvester...........................................30-1
Adjustadditionalheadlightsonforage
harvester........................................................30-1
AttachingtoaType502Forage
HarvesterwithVariableHeaderDrive............30-2
InstallingAdditionalWiringHarnessfor
theFoldingFunctionoftheRotary
HarvestingUnit...............................................30-5
InstallingAdditionalWiringHarnessfor
theStalkBuster™function..............................30-8
AttachingtoCLAASForageHarvesters...........30-10
ConnectingtheElectricalConnectors
totheForageHarvester...............................30-11
RotaryHarvestingUnitswith
Multi-SpeedGearboxandQuickCoupler....30-12
DetachingtheRotaryHarvestingUnit..............30-13
AttachingtoaFENDTForageHarvester
AligntheOscillatingFrame.................................35-1
Continuedonnextpage
OriginalInstructions.Allinformation,illustrationsandspecificationsinthis
manualarebasedonthelatestinformationavailableatthetimeofpublication.
Therightisreservedtomakechangesatanytimewithoutnotice.
COPYRIGHT©2021
JohnDeereGmbH&Co.KGMannheimRegionalCenter
Zentralfunktionen
Allrightsreserved.
AJohnDeereILLUSTRUCTION™Manual
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Contents
Page
AttachtheRotaryHarvestingUnitto
FENDTForageHarvesters............................35-1
Driveline..............................................................35-4
ConnectDriveline...............................................35-4
ChangetheHydraulicSystem............................35-5
UnlocktheOscillatingFrame..............................35-6
DetachingtheRotaryHarvestingUnit................35-6
Transport
TransportInformation.........................................40-1
FoldingtheRotaryHarvestingUnit.....................40-1
ApplyDecal(RotaryHarvestingUnits
withSupportWheel).......................................40-1
DrivingonPublicRoads(Rotary
HarvestingUnitswithComfort
SupportWheel)..............................................40-2
DrivingonPublicRoads(Rotary
HarvestingUnitswithoutComfort
SupportWheel)..............................................40-3
SetAHC-SensorintoTransportPosition............40-3
OperatingtheRotaryHarvestingUnit
MethodofOperatingtheRotary
HarvestingUnit...............................................45-1
OperatingtheRotaryHarvestingUnit-
GeneralUse...................................................45-2
ClearBlockages.................................................45-2
ClearBlockagesonCLAASForage
Harvesters......................................................45-2
AdjustingtheCentralFeedBar..........................45-3
AdjustingtheSkidShoes....................................45-4
StalkBuster™mulchingunits–theory
ofoperation....................................................45-5
AdjusttheHeightofStalkBuster™
ScraperSheets..............................................45-7
ActivatetheStalkBuster™Functionon
FENDTForageHarvesters............................45-8
ActivatingtheStalkBuster™Function
onClaasForageHarvesters........................45-10
AdjustStalkBuster™ContactPressure............45-10
Harvestingwithdeactivated
StalkBuster™function..................................45-11
AdjustingGearSelectionwith
Multi-SpeedGearboxforCLAAS
ForageHarvesters.......................................45-12
LengthsofCutandGearSelectionwith
Multi-SpeedGearboxforCLAAS
ForageHarvesters.......................................45-13
Harvesting........................................................45-14
HydraulicSystem..............................................45-14
Accessories
SpecialKitforRowGuidance(Steering
Assistance).....................................................50-1
SpecialKitforAHC.............................................50-1
Page
Troubleshooting
460plusStalkBuster™Rotary
HarvestingUnit...............................................55-1
LubricationandPeriodicService
ServiceIntervals.................................................60-1
Grease................................................................60-1
Low-ViscosityGreaseforGears.........................60-1
TransmissionOil.................................................60-2
CoolantforMainDriveFrictionClutch................60-2
AlternativeandSyntheticLubricants..................60-3
MixingLubricants................................................60-3
LubricantStorage...............................................60-3
UseGenuineKEMPERParts............................60-3
ReleasingPneumaticPressurefrom
theStalkBuster™Units..................................60-4
AttheStartofEveryHarvestingSeason............60-4
AttheStartofEveryHarvesting
Season—SphericalCollarBolts.....................60-5
AttheStartofEveryHarvesting
Season—GearboxMountingFlange
AttachingScrews...........................................60-6
OverviewofTransmissionsandOilLevels.........60-7
OverviewoftheOilLevelsintheClaas
Multi-speedGearbox......................................60-8
OilHandPumpfortheOilChangein
StalkBuster™Transmissions.........................60-8
ChangingOilinStalkBuster™Transmissions....60-9
Every10Hours—CheckandClean..................60-11
Every10Hours—CleanersandBlade
RotorSegments...........................................60-13
Every10Hours—BalancingWeights...............60-13
Every10Hours—DriveShaft...........................60-14
Every10Hours—StalkBuster™
ControlValve................................................60-14
Every10Hours—StalkBuster™
Accumulators...............................................60-15
Every50Hours—ClawClutch..........................60-15
Every50Hours—LowerPinof
HydraulicCylinderandHingesof
theOuterUnits.............................................60-16
Annually—CheckandClean.............................60-16
Every3Years—ChangeCoolantof
MainDriveFrictionClutch............................60-17
AfterEachHarvestingSeason.........................60-18
Service
MetricBoltandScrewT orqueValues.................65-1
ReleasingPneumaticPressurefrom
theStalkBuster™Units..................................65-2
RelievingPressureattheSlipClutches
ontheMainDrive...........................................65-3
DisassembleSlipClutch.....................................65-4
InstallingNewRotatingBlades...........................65-5
InstallingRigidStalkBuster™Rotors..................65-7
Continuedonnextpage
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Contents
Page
InstallingArticulatedStalkBuster™
Rotors(Option)...............................................65-8
AdjustingGathererPoints.................................65-10
CheckingScrapersAdjustment........................65-10
CheckingandAdjustingCleaners....................65-11
CleaningRotaryHarvestingUnit......................65-12
Storage
StorageatEndofHarvestingSeason................70-1
StartofNewSeason...........................................70-1
TechnicalSpecifications
MachineDesignLife...........................................75-1
460plusStalkBuster™Rotary
HarvestingUnit...............................................75-1
SoundLevel........................................................75-1
ECDeclarationofConformity.............................75-2
SerialNumber
RotaryHarvestingUnitSerialNumberPlate......80-1
SerialNumber.....................................................80-1
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Contents
iv
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PredeliveryInspection
KM00321,0000940-19-24APR19-1/1
KM00321,0000941-19-24APR19-1/1
KM00321,0000942-19-29MAY19-1/1
PredeliveryChecklist
Aftertherotaryharvestingunithasbeencompletely
assembled,inspectittobesureitisingoodrunningorder
beforedeliveringittothecustomer.Checkoffeachitem
whenfoundsatisfactoryoraftermakingthenecessary
adjustments.
□Allshieldsopenandclosefreely.
□Rotaryharvestingunithasbeenproperlyassembled.
□Partsdeliveredseparatelyhavebeenproperlyinstalled.
□Allscrewsandnutshavebeentightenedtospecified
torque.Payparticularattentiontothescrewsthatholdon
theknives.Complywiththetighteningtorquesquotedin
theServicesection.
□Allgreasefittingshavebeenlubricated.
□Allthegearcaseshavebeenfilledwiththecorrect
quantityofthecorrectoil/grease/coolant(seeLubrication
andPeriodicServicesection).
□Rotaryharvestingunitcanbefoldedcorrectly.
□Rotaryharvestingunithasbeencleanedandtouched
upwhereverpaintisnickedorscratched.
□Allmovingpartsareworkingfreely.
□CheckallslipclutchesasshownintheServicesection.
□Alldecalsareinplaceandingoodcondition.
□Thisrotaryharvestingunithasbeentestedand,tothe
bestofmyknowledge,isreadyfordeliverytothecustomer.
(DateT ested)(SignatureofTechnician)
DeliveryChecklist
Thefollowingchecklistisareminderofveryimportant
informationwhichshouldbeconveyeddirectlytothe
customerwhendeliveringthemachine.
□Thecustomerhasbeenadvisedthatthelifeexpectancy
ofthisoranyothermachinedependsonregularlubrication
asdescribedinthisoperator'smanual.
□Properharvestingmanagementpracticeshavebeen
discussed;thesearerequiredforgoodsilage.
□Thisoperator'smanualhasbeenhandedovertothe
customerandalltheoperatingadjustmentshavebeen
fullyexplained.
□Thecustomerhasbeenadvisedofthesafety
precautionsthatmustbeobservedwhileusingtherotary
harvestingunit.
□Thecustomerhasbeeninvitedtocomeinanddiscuss
anyproblemsthatmaybeencounteredwhileoperating
therotaryharvestingunit.
□Thecustomerhasbeentoldtorecordtheserialnumber
ofhisrotaryharvestingunitinthespaceprovidedinthe
SerialNumbersection.
□Thispagehasbeenfilledoutandremovedforfiling.
(SignatureofTechnician)(SignatureofCustomer)
After-SaleChecklist
Thefollowingitemsshouldbecheckedonthenewrotary
harvestingunitatthestartoftheharvestingseason.
□Allscrewsandnutshavebeentightenedtospecified
torque.Payparticularattentiontothescrewsthatholdon
theknives.Complywiththetighteningtorquesquotedin
the“Service”section.
□Allsafetyshieldsareinplaceandfastenedsecurely.
□Checkforbrokenordamagedparts.Replaceany
brokenordamagedpartswithgenuinespareparts.
□Ifpossible,runtherotaryharvestingunittoseeifitis
functioningproperly.
□Onceagaindiscussproperharvestingmanagement
practices;thesearerequiredforgoodsilage.
□Reviewtheentireoperator'smanualtogetherwithyour
customerandstresstheimportanceofproperandregular
lubrication,aswellassafetyprecautions.
(SignatureofTechnician)(SignatureofCustomer)
CLIST-1
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IdentificationView
KM00321,0000A74-19-12MAY20-1/1
IdentificationView
KM410707—UN—12MAY20
460plusStalkBuster™RotaryHarvestingUnit
00-1
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Safety
DX,ALERT-19-29SEP98-1/1
KM00321,0000A75-19-13MAY20-1/1
DX,SIGNAL-19-05OCT16-1/1
RecognizeSafetyInformation
Thisisasafety-alertsymbol.Whenyouseethissymbol
onyourmachineorinthismanual,bealerttothepotential
forpersonalinjury.
Followrecommendedprecautionsandsafeoperating
practices.
T81389—UN—28JUN13
FollowSafetyInstructions
Carefullyreadallsafetymessagesinthismanualandon
yourmachinesafetysigns.Keepsafetysignsingood
condition.Replacemissingordamagedsafetysigns.Be
surenewequipmentcomponentsandrepairpartsinclude
thecurrentsafetysigns.Replacementsafetysignsare
availablefromyourKEMPERdealer.
Beforeyoustartworkingwiththemachine,learnhowto
operatethemachineandhowtousecontrolsproperly.Do
notletanyoneoperatewithoutinstruction.
Keepyourmachineinproperworkingcondition.
Unauthorizedmodificationstothemachinemayimpairthe
functionand/orsafetyandaffectmachinelife.
Ifyoudonotunderstandanypartofthismanualandneed
assistance,contactyourKEMPERdealer.
TS201—UN—15APR13
UnderstandSignalWords
DANGER;ThesignalwordDANGERindicatesa
hazardoussituationwhich,ifnotavoided,willresultin
deathorseriousinjury.
WARNING;ThesignalwordWARNINGindicatesa
hazardoussituationwhich,ifnotavoided,couldresultin
deathorseriousinjury.
CAUTION;ThesignalwordCAUTIONindicatesa
hazardoussituationwhich,ifnotavoided,couldresultin
minorormoderateinjury.CAUTIONmayalsobeused
toalertagainstunsafepracticesassociatedwithevents
whichcouldleadtopersonalinjury.
Asignalword—DANGER,WARNING,orCAUTION—is
usedwiththesafety-alertsymbol.DANGERidentifies
themostserioushazards.DANGERorWARNING
safetysignsarelocatednearspecifichazards.General
TS187—19—30SEP88
precautionsarelistedonCAUTIONsafetysigns.
CAUTIONalsocallsattentiontosafetymessagesinthis
manual.
05-1
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Safety
FX,ROAD-19-01MAY91-1/1
DX,ABILITY-19-07DEC18-1/1
KM00321,0000A76-19-13MAY20-1/1
ObserveRoadTrafficRegulations
Alwaysobservelocalroadtrafficregulationswhenusing
publicroads.
H28930—UN—30JUN89
OperatorAbility
•Machineownersmustmakesurethatoperators
areresponsible,trained,havereadtheoperating
instructionsandwarnings,andknowhowtooperatethe
machineproperlyandsafely.
•Age,physicalability,andmentalcapacitycanbefactors
inmachine-relatedinjuries.Operatorsmustbementally
andphysicallycapableofaccessingtheoperatorstation
and/orcontrols,andoperatingthemachineproperly
andsafely.
•Neverallowachildoranuntrainedpersontooperate
themachine.Instructalloperatorsnottogivechildrena
rideonthemachineoranattachment.
•Neveroperatemachinewhendistracted,fatigued,
orimpaired.Propermachineoperationrequiresthe
operator’sfullattentionandawareness.
UseSafetyLightsandDevices
Preventcollisionswithotherroadusers.Slowmoving
tractorswithimplementsordrawnequipment,aswell
asself-propelledmachinesareespeciallydangerouson
publicroads.Alwayspayattentiontotrafficapproaching
frombehind,particularlywhenchangingdirection.Provide
forsafetrafficconditionsbyusingturnsignals.
Useheadlights,hazardwarninglights,turnsignalsand
othersafetydevicesaccordingtothelocalregulations.
Keepsafetydevicesingoodcondition.Replacemissing
ordamageditems.
TS951—UN—12APR90
05-2
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